wtw PurCon IS sample preparation Operating instructions

Brand: wtw

Model: PurCon IS sample preparation

Type: Operating instructions

ba43133e06 05/2009

PurCon IS

Sample preparation

Operating manual

PurCon IS

ba43133e06 05/2009

Accuracy when going to

press

The use of advanced technology and the high quality of our instruments

are the result of continuous development. This may result in differences

between this operating manual and your instrument. Also, we cannot

guarantee that there are absolutely no errors in this manual. Therefore,

we are sure you will understand that we cannot accept any legal claims

resulting from the data, figures and descriptions.

Reprinting - even as excerpts - is only allowed with the explicit written

authorization of WTW GmbH, Weilheim.

Printed in Germany.

PurCon IS Contents

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PurCon IS - Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.2 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1.2.1 Filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1.2.2 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.2.3 Permeate suction line . . . . . . . . . . . . . . . . . . . . 57

1.2.4 Permeate line . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.1 Authorized use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.2 Name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 60

3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.2.2 Filter unit and permeate suction line . . . . . . . . . 63

3.2.3 Terminal box and permeate line . . . . . . . . . . . . 68

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.1 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.2 Starting sample preparation . . . . . . . . . . . . . . . . . . . . . . 74

4.3 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . . 75

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.1 Cleaning the filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.1.1 Removing and installing the filter . . . . . . . . . . . 78

5.1.2 Cleaning the filter unit . . . . . . . . . . . . . . . . . . . . 80

5.2 Displacing the pump tubings . . . . . . . . . . . . . . . . . . . . . 82

5.3 Replacing pump tubings . . . . . . . . . . . . . . . . . . . . . . . . . 84

5.4 Cleaning the air filter of the compressor . . . . . . . . . . . . 86

5.5 Cleaning the control unit . . . . . . . . . . . . . . . . . . . . . . . . 87

6 What to do if ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

6.1 Replacing the filter plates . . . . . . . . . . . . . . . . . . . . . . . . 90

6.2 Replacing the permeate tubes (suction side) . . . . . . . . . 90

Contents PurCon IS

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7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.1 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.2 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . 93

7.3 Data of permeate supply . . . . . . . . . . . . . . . . . . . . . . . . . 94

8 Accessories and consumable materials . . . . . . . . . . . 95

PurCon IS Introduction

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1 Introduction

1.1 General information

PurCon IS sample preparation prepares the sample for the analysis of

component substances with analyzers. PurCon IS uses the most mod-

ern technologies that enable largely maintenance-free and long-term

operation.

In comparison to conventional sample preparations, the maintenance

costs of the PurCon IS are low. Due to the low dwell time of the sample

in the PurCon IS, the preparation is carried out without any effect on

existing component substances. The sample preparation is carried out

continuously. The permeate is free from germs and total suspended

solids so that analyzers can be operated with very high reliability.

The maintenance costs of the analyzers are reduced considerably if

PurCon IS is used for the sample preparation.

Introduction PurCon IS

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1.2 Structure and function

PurCon IS consists of the following main components:

z Filter unit

z Control unit

1.2.1 Filter unit

Fig. 1-1 Filter unit

1 Framework

2 Filter

3 Air shower

4 Permeate suction pipeline

5 Suction tube

PurCon IS Introduction

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The filter unit is immersed in the sample. The filter unit has 2 or 4 filters

depending on the version. The front and back of the filter are used as

a filter membrane. The sample is sucked into the inside of the filter by

the permeate pump of the control unit. The filtered sample ("permeate")

is forwarded to the analyzer by the control unit.

BubbleClean procedure

for the self cleaning

A powerful jet of air is blown onto the outside of the filter from below.

This forces a continuous flow of sample that inhibits the pollution of the

filter membrane. This considerably reduces the overheads for cleaning

the filter.

The filter unit is connected with the control unit via the permeate suction

pipeline. Amongst other things, the control unit contains the air com-

pressor for the self cleaning and the permeate pump (see section

1.2.2 C

ONTROL UNIT).

Introduction PurCon IS

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1.2.2 Control unit

Main components of the

control unit

Fig. 1-2 Control unit (example with heating line for the permeate line)

1 Operating panel

2 Control electronics

3 Permeate valve (3/2 port valve)

4 Air compressor

5 Permeate suction tube (back)

6 Permeate line (front)

7 Permeate pump

PurCon IS Introduction

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The operation and control of PurCon IS is carried out by the control

unit. It contains all the control and monitoring facilities that are required

for the permeate extraction and forwarding. The air compressor for the

BubbleClean self cleaning system is also contained in the control unit.

Permeate pump The permeate is fed by a peristaltic pump with four pump channels. The

pump output can be adjusted in four stages.

1.2.3 Permeate suction line

The permeate suction line connects the filter unit with the control unit.

It consists of three components:

z 2 permeate hoses (inside diameter 4 mm). These are used to feed

the permeate from the membrane plates.

z Encasing tube. It is used as a protective covering for the two perme-

ate tubes. At the same time, the air shower of the filter unit is sup-

plied with compressed air from the air compressor via the encasing

tube.

Integrated protection

against freezing

The compressed air flowing through the encasing tube is warmed by

the air compressor. This ensures that, when outside temperatures are

low, the permeate does not freeze on its way through the permeate

hoses.

1.2.4 Permeate line

The permeate line forwards the permeate from the control unit to the

analyzers. It consists of the following parts:

z Encasing tube.

z Permeate hose (inside diameter 2 mm)

z Terminal box

z Heating line (option).

Terminal box On the analyzer side, the permeate tube is connected to a box (terminal

box). The permeate is delivered to the analyzer or overflow vessel via

a hose nipple.

Protection against

freezing

(option)

The permeate can be protected against freezing with the aid of a heat-

ing line. The temperature monitoring is carried out with the aid of a tem-

perature sensor that is integrated in a freely placeable cable box

("temperature measuring box"). The temperature measuring box is

connected with the control unit. If there is any danger of the permeate

freezing, the control electronics switch the heating line on.

Introduction PurCon IS

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PurCon IS Safety instructions

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2 Safety instructions

This operating manual contains essential instructions that must be fol-

lowed during the commissioning, operation and maintenance of the

instrument.

Consequently, all responsible personnel must read this operating man-

ual carefully before working with the instrument. The operating manual

must always be kept available within the vicinity of the instrument.

General safety

instructions

Safety instructions in the operating manual are indicated by the

warning symbol (triangle) in the left column. The signal word

(e. g. "CAUTION") indicates the danger level:

WARNING

indicates instructions that must be followed precisely in order to

prevent serious danger to personnel.

CAUTION

indicates instructions that must be followed precisely in order to

avoid slight injuries to personnel or damage to the instrument or

the environment.

Other labels

Note

indicates notes that draw your attention to special features.

Note

indicates cross-references to other documents, e.g. component oper-

ating manuals.

2.1 Authorized use

Authorized use consists exclusively of the preparation of samples for

the analysis of component substances using analyzers. The technical

specifications given in chapter 7 T

ECHNICAL DATA must be followed. Any

other use is considered to be unauthorized.

2.2 Name plate

The name plate of the PurCon IS is located on the inside of the door of

the control unit housing.

Safety instructions PurCon IS

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2.3 General safety instructions

This instrument is constructed and inspected in accordance with the

relevant guidelines and norms for electronic measuring instruments

(see chapter 7 T

ECHNICAL DATA).

It left the factory in a safe and secure technical condition.

Function and

operational safety

The failure-free function and operational safety of the instrument is only

guaranteed if the generally applicable safety measures and the special

safety instructions in this operating manual are followed during its use.

The failure-free function and operational safety of the PurCon IS is only

guaranteed under the environmental conditions that are specified in

chapter 7 T

ECHNICAL DATA.

If the instrument was transported from a cold environment to a warm

environment, the formation of condensate can impair the functioning of

the instrument. In this case, wait for the instrument to adjust to room

temperature before recommissioning.

Safe operation If safe operation is no longer possible, the instrument must be taken out

of operation and secured against inadvertent operation.

Safe operation is no longer possible if the instrument:

z has been damaged in transport

z has been stored under adverse conditions for a lengthy period of

time

z is visibly damaged

z no longer operates as described.

If you are in any doubt, contact the supplier of your instrument.

PurCon IS Commissioning

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3 Commissioning

3.1 Scope of delivery

PurCon IS/2-230

PurCon IS/4-230

z Control unit

z Temperature measuring box

z Filter unit with 2 or 4 filters

z Permeate suction line

z Operating manual

PCIS-PL... Permeate line with terminal box (different lengths, with or without hea-

ting line). Permeate line with terminal box must be ordered seperately.

3.2 Installation

CAUTION

The mounting of the PurCon IS may only be carried out by special-

ists authorized by WTW. WTW reserves the right to reject warranty

claims if this condition is violated.

Commissioning PurCon IS

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3.2.1 Control unit

Types of mounting The control unit can be mounted in the following ways in the vicinity of

the sampling location:

z Rail mounting with the PCIS-MSG accessory set

z Wall mounting (see below)

Note

Instructions for mounting are given in the mounting instructions of the

accessories. Ordering information for the accessories are given in sec-

tion 8 A

CCESSORIES AND CONSUMABLE MATERIALS.

Wall mounting The housing of the control unit has four attaching eyes on the back for

mounting on a wall. Make sure that the wall has the stability required

for the weight of the control unit. Only use mounting material, which is

suitable for the wall material (screws, dowels, etc.). The drilled hole

spacings are shown in the following diagram:

Fig. 3-1 Drilled hole spacings for the control unit (dimensions in mm)

Note

Make sure that there is sufficient space under the control unit for con-

necting the permeate suction tube and the permeate line.

Rail mounting Alternatively, the control unit can be mounted on a railing.

533

355

PurCon IS Commissioning

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3.2.2 Filter unit and permeate suction line

Types of mounting The filter unit can be mounted on site in the following ways:

z Chain mounting with the PCIS-MSK accessory set

z Pipe mounting with the PICS-MSS accessory set, e.g. on the railing

Note

Observe the minimum immersion depth of the filter unit (see dimensio-

nal drawing in chapter 7 T

ECHNICAL DATA. The frame tube must be enti-

rely immersed.

Note

Instructions for mounting are given in the mounting instructions of the

accessories. Ordering information for the accessories are given in sec-

tion 8 A

CCESSORIES AND CONSUMABLE MATERIALS.

Connecting the

permeate suction line

with the filter unit

Fig. 3-2 Connecting the permeate suction line with the filter unit

1 Remove the coupling nut (pos. 1 in Fig. 3-2) and the threaded

plugs (pos. 2).

2 Push a hose clip (pos. 3) over the encasing tube (pos. 4).

3 Thread the two suction hoses (pos. 5) through the compressed

air connection (pos. 5).

4 Slip the encasing tube on the compressed air connection and

secure with the hose clip.

Commissioning PurCon IS

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Fig. 3-3 Connecting the permeate suction hoses

5 Push the threaded plugs (pos. 2) over the two suction tubes up

to the cable gland (pos. 6) and secure with the coupling ring

(pos. 1). The flat side of the threaded plug must face down-

wards.

6 Connect the two suction hoses with the filter as shown in the

following Fig. 3-3. In the case of four filters, connect filters 1

and 3, as well as 2 and 4 to an intake tube via Y pieces.

PurCon IS Commissioning

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Connecting the

permeate suction line

with the control unit

WARNING

Touching the electrical lines inside the control unit can result in

danger to life from electric shock. Before opening the operating

panel of the instrument, switch it off at the mains switch and pull

out the mains plug.

Fig. 3-4 Preparing the control unit

1 Open the door of the control unit.

2 Remove the screw (pos. 1 in Fig. 3-4) and open the operating

panel (pos. 2).

3 Undo the back cable gland (pos. 3 in Fig. 3-4).

Netz

Commissioning PurCon IS

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Fig. 3-5 Mounting the permeate suction hose

4 Remove the coupling nut (pos. 4 in Fig. 3-5) from the cable

glands and remove the threaded plug (pos. 5).

5 Thread the two suction hoses (pos. 6a and 6b) from below

through the terminal block (pos. 7).

6 Push the encasing tube (pos. 8) through the cable gland into

the terminal block up to the stop. Twist the encasing tube

somewhat while doing so. The encasing tube is pushed in far

enough when the marking on the hose lines up with the cable

gland. Then tighten up the cable gland.

7 Push the threaded plugs (pos. 5) over the two suction tubes up

to the cable gland and secure with a coupling ring (pos. 5). The

flat side of the threaded plug must face upwards.

6a, b

PurCon IS Commissioning

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Fig. 3-6 Connecting the suction lines to the permeate valve

8 Connect the two suction tubes with the free connections of the

permeate valve (pos. 9a and 9b in Fig. 3-6).

Commissioning PurCon IS

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3.2.3 Terminal box and permeate line

One end of the permeate line is already connected with the terminal

box in the factory. The following main steps are necessary for mounting

the unit:

z Mounting the terminal box in the vicinity of the analyzer

z Connecting the terminal box with the analyzer

z Connecting the free end of the permeate line with the control unit.

Note

The terminal box should be mounted in the immediate vicinity of the

analyzer if possible in order to avoid long distances to the permeate

and the dead times associated with it.

Mounting the

terminal box

Fig. 3-7 Mounting the terminal box

1 Open the terminal box.

2 Screw the terminal box onto a flat wall surface via the four

drilled holes at the corners (Fig. 3-7). Use suitable screws

(max. diameter 5 mm).

3 Close the terminal box.

Permeate output

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wtw PurCon IS sample preparation Operating instructions

wtw PurCon IS sample preparation Operating instructions

wtw PurCon IS sample preparation Operating instructions

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